Frequently Asked Questions

Dura-Lite™ is a Customer Service driven company and we want to take every opportunity we can to talk to and help out our customers. We feel by having customers contact Dura-Lite™ Customer Support at 800-661-1117 we can serve them more effectively. We will not only offer information on the nearest Distributor/ Dealer, but will also help to source the product you are looking for.

Dura-Lite™ has manufacturing facilities in North America, Australia, and Asia. The origin of a specific part can vary from time to time, dependent on demand and plant capacity. All production, regardless of the plant location, is built to Dura-Lite's specifications with Dura-Lite™ production staff.

No. Repairing a leaking Original Equipment style Charge Air Cooler is nothing more than a band-aid and it will end up costing you more in down time when it leaks again. If the original design wouldn’t last, how can a patch repair be expected to? The cost of a new Charge Air Cooler will ultimately be far less than the loss of fuel economy you will experience as the cooler leaks more each day. You also risk a potential turbo charger replacement as the turbo continues to work harder to compensate for a leaking Charge Air Cooler. In addition there is the potential for engine wear, and other issues associated with a leaking Charge Air Cooler.

No. Although there have been attempts to copy Dura-Lite’s design, Dura-Lite™ is the original inventor. Dura-Lite’s proven technology allows it to offer an industry leading (non-prorated) 7 Year/ 1,000,000 Mile Warranty on most Part #'s. Dura-Lite’s design and manufacturing process are protected under numerous patents. Companies offering imitation products are infringing on Dura-Lite’s patents and could be subject to legal action.

Dura-Lite™ refers to the seal between the tube-to-header joint as a grommet. The grommet allows the tubes to expand and contract in the grommet/ header, which eliminates the typical tube-to-header failure mode and resulting leakage.

Dura-Lite Heat Transfer Products Ltd.™ is a Professional Engineering Company, certified by APEGGA (Association of Professional Engineers, Geologists, and Geophysicists of Alberta).

Dura-Lite™ maintains its technological lead in the industry by maintaining a staff of multi-disciplined engineers, utilizing some of the most advanced software and testing equipment available in the industry.

Capabilities:

3D CAD (Computer Aided Design):

Mechanical CAD;

Design Validation;

Product Data Management;

Design Communication; and

CAD Productivity Tools.

CAD/ CAM (Computer Aided Design and Computer Aided Manufacturing):

Dura-Lite™ uses these tools to create faster production processes, components and tooling with dimensional accuracy.

After designing components in CAD software, the CAM tool is used by Dura-Lite™ to interface with and drive its CNC (Computer Numerical Control) machines to manufacture high quality parts.

FEA (Finite Element Analysis):

FEA software simulates the extreme conditions that Charge Air Coolers can be exposed to, without having to wait years for the results;

FEA can show weaknesses in designs, to allow improvements to be made before parts are manufactured and as a result, assures product durability; and

Once the FEA results have been analyzed and the design finalized, manufacturing can produce a prototype sample. The theoretical results can then be definitively confirmed with “actual” results in Dura-Lite’s Environmental Wind Tunnel Thermal Cycle Testing Equipment.

CFD (Computational Fluid Dynamics):

CFD software is used to simulate Charge Air Cooler airflow and thermal conditions to predict the performance of the design;

Theoretical analysis can be performed on a “virtual prototype”, allowing further design changes as required before the final design is completed and a Charge Air Cooler is manufactured; and

Once the CFD results have been analyzed and the design finalized, manufacturing can produce a prototype sample. The theoretical results can then be definitively confirmed with “actual” results in Dura-Lite's Environmental Wind Tunnel Performance Testing Equipment and/ or on a vehicle using the Chassis Dynamometer.

CMM (Coordinate Measuring Machine):

CMM equipment is used to measure the physical geometrical characteristics of the parts used in the manufacturing and assembly processes of Dura-Lite™ Charge Air Coolers. The measurements allow part and/ or assembly to be compared against the design intent;

Precisely recording the X, Y, and Z coordinates of a part, also allows points to be generated to construct features of a part when engineering new parts based on physical samples; and

Using this equipment allows Dura-Lite™ to ensure that our Charge Air Coolers are manufactured in accordance with the design specifications and to ensure fit and function in the application.

Yes. Dura-Lite Heat Transfer Products Ltd.™, warrants its Evolution® (and Ultimate Solution®) Charge Air Coolers under normal on-highway operating conditions to the original owner for a period of 7 (seven) years or 1,000,000 miles or 1,609,000 (one million, six hundred and nine thousand) kilometres, whichever occurs first from the date of installation. The warranty does not authorize any customer or entity to act on behalf of Dura-Lite™ in regards to warranty settlement. Dura-Lite’s warranty is not prorated and if during the warranty period a Charge Air Cooler is found to be defective, Dura-Lite™ will either repair or supply a replacement Charge Air Cooler, at no charge. If there is a problem with a Dura-Lite™ Charge Air Cooler, it will be sent back to Dura-Lite™ to determine the cause of the problem so it can be eliminated from reoccurring. This process allows Dura-Lite™ to continue to reduce its warranty rate. Dura-Lite™ has maintained a less than 1% warranty return rate over the past 20 years. All Charge Air Coolers are tested to be 100% leak free before they leave Dura-Lite’s manufacturing facility.

Most Dura-Lite™ Charge Air Coolers are backed by our industry leading (non-prorated) 7 Year / 1,000,000 Mile Warranty. Certain Part #'s carry a limited warranty ranging from 1 (one) to 3 (three) years depending upon the design and application. Distributors/ Dealers can visit Dura-Lite’s Website Catalog and/ or printed Catalog for the applicable warranty coverage on each Dura-Lite™ Charge Air Cooler. If the Part # is not available, please contact Dura-Lite™ Customer Support at 800-661-1117 for the applicable Part # and warranty coverage.

No. Although the Dura-Lite™ warranty is only valid to the original owner and the warranty is not transferable, the benefits of the Dura-Lite™ Charge Air Cooler certainly stay with the vehicle in which it is installed.

No. Dura-Lite™ Charge Air Coolers are designed to perform equal to or better than the Original Equipment Charge Air Cooler. Many Original Equipment Truck and Engine Manufacturers have selected Dura-Lite™ as their aftermarket supplier.

Open the hood or engine compartment of the vehicle and look for the Dura-Lite™ Part (Model) # and Serial # Label on the Charge Air Cooler. The Label is typically located on the top center of the Charge Air Cooler.

Dura-Lite™ recommends that a Charge Air Cooler should be tested every time the vehicle is in for service and/ or when the oil is changed. It is vital to the performance and reliability of the engine that leaks are detected as soon as possible in order to reduce problems caused by a leaking Charge Air Cooler.

Dura-Lite™ manufactures a Test Kit that includes all of the tools and instructions necessary to test most models, makes, and/ or sizes of Charge Air Coolers safely and accurately. Please reference Dura-Lite’s Tester-Kit™ information page under the Products section of the Website or printed Catalog for additional information on the basic procedure. Dura-Lite’s Part # is “Tester-Kit™” and the kit is available through Dura-Lite™ Distributors/ Dealers. The Distributor/ Dealer will provide your cost. Please contact Dura-Lite™ Customer Support at 800-661-1117 for information on a Distributor/ Dealer near you.

Yes. Dura-Lite™ manufactures a Test Kit that includes all of the tools and instructions necessary to test most models, makes, and/ or sizes of Charge Air Coolers safely and accurately. Please reference Dura-Lite’s Tester-Kit™ information page under the Products section of the Website or printed Catalog for additional information on the basic procedure. Dura-Lite’s Part # is “Tester-Kit™” and the kit is available through Dura-Lite™ Distributors/ Dealers. The Distributor/ Dealer will provide your cost. Please contact Dura-Lite™ Customer Support at 800-661-1117 for information on a Distributor/ Dealer near you.

Yes. The rule of thumb is to pressure the Charge Air Cooler up to 30 psig and that it should hold air for at least 15 seconds. If there is a pressure loss of 5 psig or more within the 15 seconds, the Charge Air Cooler is leaking out of specification (Leak Down Rate Specification) and it should be replaced immediately. This is only a guideline and it is very important to check the engine manufacturers Leak Down Rate Specification (some common specifications are noted below). Please also reference Dura-Lite’s Tester-Kit™ information page under the Products section of the Website for additional information on the basic procedure.

Leak Down Rate Specifications:

Caterpillar

5 psig in 15 seconds @ 30 psig

Cummins (ISB, ISC, N14)

7 psig in 15 seconds @ 30 psig

Cummins (ISX, M11)

5 psig in 15 seconds @ 30 psig

Detroit Diesel

5 psig in 30 seconds @ 30 psig

International

5 psig in 15 seconds @ 30 psig

Mack

5 psig in 15 seconds @ 30 psig

Mercedes

5 psig in 15 seconds @ 25 psig

Volvo

5 psig in 15 seconds @ 30 psig

* psig (pound-force per square inch gauge)

An engine with a leaking Charge Air Cooler will waste fuel. Dura-Lite’s calculation of the amount of fuel an engine is wasting as a result of a Leaking Charge Air Cooler is approximately what is shown in the table below (based on a fuel cost of $ 2.25 per gallon).

* Please also reference Dura-Lite’s Leaking CAC Calculator page on the Website to find out what you can save!

Leaking Charge Air Cooler Cost:

Fuel Cost Calculator:

Leaking
Charge Air Cooler:

Dura-Lite™
Leak Free
Charge Air Cooler:

Fuel Cost

$2.25

$2.25

Per Gallon

US Gallons

Fuel Economy

5.5

5.9

MPG (Estimate)

Average Trip Per Day

600

600

Miles

Consumption Per Day

109.1

101.7

Gallons

US Gallons

Cost Per Day

$245.45

$228.81

*

* An engine with a leaking Charge Air Cooler will waste fuel. Dura-Lite’s calculation of the amount of fuel your engine is wasting is approximately what is shown above. The calculations are only approximate amounts based on a formula, using information from customer experiences with our products. Those experiences may be different from yours. The amount you save may be more or less than what is shown, due to other factors not reflected in the calculations. Dura-Lite™ does not warrant the accuracy of the calculations.

Dura-Lite’s calculation of the amount of fuel an engine is wasting as a result of a Leaking Charge Air Cooler and an operator could save with a Dura-Lite™ Leak Free Charge Air Cooler is approximately what is shown in the table below (based on a fuel cost of $ 2.25 per gallon).

* Please also reference Dura-Lite’s Leaking CAC Calculator page on the Website to find out what you can save!

Dura-Lite™ Could Save An Operator:

Per Day*

$17.00

Per Week*

$85.00

Every 4 Weeks*

$340.00

Per Year*

$4,420.00

* An engine with a leaking Charge Air Cooler will waste fuel. Dura-Lite’s calculation of the amount of fuel your engine is wasting is approximately what is shown above. The calculations are only approximate amounts based on a formula, using information from customer experiences with our products. Those experiences may be different from yours. The amount you save may be more or less than what is shown, due to other factors not reflected in the calculations. Dura-Lite™ does not warrant the accuracy of the calculations.

An engine with a leaking Charge Air Cooler will waste fuel. Dura-Lite’s calculation of the amount of fuel an engine is wasting is approximately what is shown in the table below (based on a fuel cost of $ 2.25 per gallon).

* Please also reference Dura-Lite’s Leaking CAC Calculator page on the Website to find out what you can save!

Dura-Lite™ Could Save A Fleet:

Number Of Vehicles:

50

100

250

500

750

1,000

Per Day*

$17.00

$850.00

$1,700.00

$4,250.00

$8,500.00

$12,750.00

$17,000.00

Per Week*

$85.00

$4,250.00

$8,500.00

$21,250.00

$42,500.00

$63,750.00

$85,000.00

Every 4 Weeks*

$340.00

$17,000.00

$34,000.00

$85,000.00

$170,000.00

$255,000.00

$340,000.00

Per Year*

$4,420.00

$221,000.00

$442,000.00

$1,105,000.00

$2,210,000.00

$3,315,000.00

$4,420,000.00

* An engine with a leaking Charge Air Cooler will waste fuel. Dura-Lite’s calculation of the amount of fuel your engine is wasting is approximately what is shown above. The calculations are only approximate amounts based on a formula, using information from customer experiences with our products. Those experiences may be different from yours. The amount you save may be more or less than what is shown, due to other factors not reflected in the calculations. Dura-Lite™ does not warrant the accuracy of the calculations.

Determine the Original Equipment Part # of the Charge Air Cooler on the vehicle. Distributor/ Dealers can then cross the Part # to a Dura-Lite™ Part # on Dura-Lite’s Website Catalog and/ or printed Catalog or contact Dura-Lite™ Customer Support at 800-661-1117 for further assistance.

Open the hood or engine compartment of the vehicle and look for the Original Equipment Part # Label on the Charge Air Cooler. The Label is typically located on the top center of the Charge Air Cooler. If there isn’t a Label present, call your Dealer. Provide the vehicles V.I.N. to the Dealer and request the Original Equipment Charge Air Cooler Part #.

With the exception of some specialty Original Equipment applications, Dura-Lite™ is not available as an Original Equipment option at this time. However, the vehicle owner can specify that the Dealer install a Dura-Lite™ Charge Air Cooler on the vehicle, prior to delivery.

No. Dura-Lite™ sells its products through extensive distribution channels of Distributors/ Dealers and does not sell directly to the end user. Please contact Dura-Lite™ Customer Support at 800-661-1117 for information on a Distributor/ Dealer near you.

Dura-Lite™ sells its products through extensive distribution channels of Distributors/ Dealers and does not sell directly to the end user. The Distributor/ Dealer will provide your product cost. Please contact Dura-Lite™ Customer Support at 800-661-1117 for information on a Distributor/ Dealer near you.

Dura-Lite™ is a Customer Service driven company and we want to take every opportunity we can to talk to and help out our customers. We feel by having customers contact Dura-Lite™ Customer Support at 800-661-1117 we can serve them more effectively. We will not only offer information on the nearest Distributor/ Dealer, but will also help to source the product you are looking for.

The price of Original Equipment Charge Air Coolers varies widely. Dura-Lite™ Charge Air Coolers are very competitively priced vs. the Original Equipment. Dura-Lite’s value is beyond the price and we offer an incomparable (non-prorated) 7 Year / 1,000,000 Mile Warranty on most Charge Air Cooler Part #'s. The warranty is covered across North America.

Dura-Lite™ products are available through extensive distribution channels of Distributors/ Dealers and Dura-Lite™ does not sell directly to the end user. Please contact Dura-Lite™ Customer Support at 800-661-1117 for information on a Distributor/ Dealer near you. Distributors/ Dealers Orders received by 2:00 PM MST (Mountain Standard Time) for products in stock will be shipped the same day.

Yes. Dura-Lite™ products are available through extensive distribution channels of Distributors/ Dealers and Dura-Lite™ does not sell directly to the end user. Please contact Dura-Lite™ Customer Support at 800-661-1117 for information on a Distributor/ Dealer near you. Next day service is available to Distributors/ Dealers for most Charge Air Coolers shipped to many cities in North America. Please contact Dura-Lite™ Customer Support at 800-661-1117 for additional information.

Dura-Lite™ currently manufactures over 600 different Charge Air Coolers and we have an extensive inventory to support our product offering. Dura-Lite’s professionally certified engineers can also custom design a Charge Air Cooler, Radiator, and/ or Radiator/ Charge Air Cooler Cooling Module for any application.

Dura-Lite™ sells its products through extensive distribution channels of Distributors/ Dealers and does not sell directly to the end user. Dura-Lite’s Part # is “Tester-Kit™” and the Distributor/ Dealer will provide your cost. Please contact Dura-Lite™ Customer Support at 800-661-1117 for information on a Distributor/ Dealer near you.

Dura-Lite’s offers an incomparable (non-prorated) 7 Year / 1,000,000 Mile Warranty on most Charge Air Cooler Part #'s. The warranty is covered across North America. Dura-Lite™ has a proven track record with more than 20 years of experience in the heat transfer business. Dura-Lite’s Charge Air Coolers lead the industry in both quality and durability, which allows them to outlast any other Charge Air Coolers in the marketplace today.

It’s not possible to successfully repair a tube-to-header leak on a Charge Air Cooler and any repair made would simply be a temporary fix. At $2.25 per gallon, a leak free Dura-Lite™ Charge Air Cooler could save you $4,420.00 or more per year. Dura-Lite™ Charge Air Coolers have a (non-prorated) 7 Year / 1,000,000 Mile Warranty on most Part #'s and the warranty is covered across North America.

Dura-Lite™ manufactures the best Charge Air Coolers in the world, backed by the best warranty in the business with North American coverage. Other companies may advertise a longer warranty period, but the warranties are typically prorated with exceptions, exclusions and do not have North American coverage to support the product.

Dura-Lite™ Patented Silicone Grommet Tube-To-Header Seal System allows the tubes to expand and contract in the grommet/ header. This eliminates the typical tube-to-header failure mode and resulting leakage.

The Dura-Lite™ Offset Outer Fin design provides consistent performance by minimizing the build up of debris.

Manufactured leak free.

Engineered for performance, EPA Certified.*

* Where required, our product has been certified to EPA standards. The United States Environmental Protection Agency (EPA) program “Self-Certification of After-Market Parts” is aimed at allowing after market manufacturers of light-duty automotive parts to certify their products to EPA emission standards to ensure that using these parts to replace the Original Equipment parts will not result in adverse effect on the applicable vehicle emissions. Dura-Lite™ has taken the initiative to certify its product where applicable through this program. This involved extensive testing in accordance with EPA and SAE recommended test procedures. The test results were compared to Original Equipment Manufacturers data and EPA emission standards with favorable results. The implication of this certification is that, based on the test results, the effect on vehicle emissions, of using a Dura-Lite™ Charge Air Cooler in a truck will be the same as or better than using its Original Equipment Manufacturer counterpart.

Dura-Lite™ Evolution® Warranty:

The Evolution® features allow Dura-Lite™ to offer a (non-prorated) 7 Year / 1,000,000 Mile Warranty on most Charge Air Coolers.*

North American Warranty Coverage.

Less than 1% warranty return.

* On most Charge Air Cooler Part #'s. Distributors/ Dealers can visit Dura-Lite’s Website Catalog and/ or printed Catalog for the applicable warranty coverage on each Dura-Lite™ Charge Air Cooler. If the Part # is not available, please contact Dura-Lite™ Customer Support at 800-661-1117 for the applicable Part # and warranty coverage.

Dura-Lite™ Evolution® Benefits:

Continuous, consistent fuel economy.

Optimized power and emissions.

Reduced downtime.

Superior quality and warranty.

The most reliable Charge Air Cooler in the world.

Dura-Lite™ Channel Flow® Features:

Designed for (but not limited to) Agricultural and Industrial Applications.

Designed for applications where dust, dirt, and debris cause the outside of the Original Equipment Charge Air Cooler to become plugged up.

Manufactured with the standard features incorporated in Dura-Lite’s Evolution® Charge Air Coolers.

Superior quality and 1 Year Warranty.

North American Warranty Coverage.

0% Warranty returns to date.

Why Dura-Lite™ Charge Air Coolers:

All-Makes product coverage with over 600 production Part #’s for any diesel application. Additional Part #’s added continually.

Dura-Lite™ offers the best warranty in the business (non-prorated) 7 Year/ 1,000,000 Mile Warranty.*

Less than 1% failure rate.

North America Warranty Coverage.

Warranty backed by the factory.

No costly downtime.

Reduced overall fuel costs. A non-performing Charge Air Cooler will cost more in fuel. At $2.25 per gallon, a leak free Dura-Lite™ Charge Air Cooler could save you $4,420.00 or more per year.

* On most Charge Air Cooler Part #'s. Distributors/ Dealers can visit Dura-Lite’s Website Catalog and/ or printed Catalog for the applicable warranty coverage on each Dura-Lite™ Charge Air Cooler. If the Part # is not available, please contact Dura-Lite™ Customer Support at 800-661-1117 for the applicable Part # and warranty coverage.

Original Equipment plastic tank radiators typically fail at the joint between the plastic tank and the aluminum header/ core. Dura-Lite™ has eliminated this failure mode by replacing the plastic tanks and aluminum core with either Bolt-On (steel) or Solder-On (brass) reinforced tanks and copper/ brass core.

All Dura-Lite™ radiator tanks and structure are made of high strength, heavy gauge rust resistant steel or brass.

Dura-Lite™ has made improvements to the Original Equipment radiator design to reinforce areas commonly prone to failure.

All-Makes replacements for most applications. Additional Part #’s added continually.

No Core Charge on all Radiators.

Comprehensive unlimited mileage 2 Year Warranty. *

North American Warranty Coverage.

Dura-Lite’s Engineering Department can custom design a Radiator or Radiator / Charge Air Cooler Cooling Module for any application.

* Most Dura-Lite™ Radiators are backed by a 2 Year Warranty. Certain Part #'s carry a 1 (one) year warranty depending upon the design and application. Distributors/ Dealers can visit Dura-Lite’s Website Catalog and/ or printed Catalog for the applicable warranty coverage on each Dura-Lite™ Radiator. If the Part # is not available, please contact Dura-Lite™ Customer Support at 800-661-1117 for the applicable Part # and warranty coverage.

Why Dura-Lite™ Radiators:

Superior quality and durability utilizing proven technology.

All-Makes replacements for most applications. Additional Part #’s added continually.

Comprehensive unlimited mileage 2 Year Warranty.

North America Warranty Coverage.

Warranty backed by the factory.

No costly downtime.

* Most Dura-Lite™ Radiators are backed by a 2 Year Warranty. Certain Part #'s carry a 1 (one) year warranty depending upon the design and application. Distributors/ Dealers can visit Dura-Lite’s Website Catalog and/ or printed Catalog for the applicable warranty coverage on each Dura-Lite™ Radiator. If the Part # is not available, please contact Dura-Lite™ Customer Support at 800-661-1117 for the applicable Part # and warranty coverage.